Method for maintaining the separation of plates

ABSTRACT

A method and apparatus are disclosed for maintaining a predetermined separation between the walls of light valves, especially when the pressure on the inside of the walls may be less than the pressure on the outside of the same walls (atmospheric pressure). To maintain this separation, a plurality of small chemically inert, non-deformable beads are added to the fluid suspension in the light valve. These beads which have at least one dimension which is the same as the desired spacing between the walls distribute themselves throughout the suspension to prevent the pressure differential from causing the walls to come closer together than the predetermined distance between them and thereby help to assure the proper operation of the light valve.

iza-1s 5R waited ates Lowell set 1 1 METHQD FUR MAlNTAlNlNG THE SEPARATKON OF PLAT [75] lnventor: Francis C. Lowell, Huntington Station, NY.

[73] Assignee: Research Frontiers incorporated, Plainview, NY.

[22] Filed: July 26, 1971 [21] Appl. No.: 166,038

[52] US. Cl 29/592, 29/421, 161/45,

264/2, 264/88, 350/150, 350/267 [51] km. Cl. 1101s 4/00 [58] Field of Search 29/421, 422, 592;

[451 July 3, 1913 FOREIGN PATENTS OR APPLICATIONS 487,032 6/1938 Great Britain 1,108,593 4/1968 Great Britain 1,138,992 1/1969 lGreat Britain Primary Examiner-Charles W. Lanham Assistant Examiner-V. A. Dipalrna ,1 Attorney-Stephen E. Feldman [57] ABSTRACT A method and apparatus are disclosed for maintaining a predetermined separation between the walls of light valves, especially when the pressure on the inside of the walls may be less than the pressure on the outside of the same walls (atmospheric pressure). To maintain this 7 separation, a plurality of small chemically inert, nondeformable beads are added to the fluid suspension in the light valve. These beads which have at least one d imension which is the same as the desired spacing between the walls distribute themselves throughout the suspension to prevent the pressure differential from causing the walls to come closer together than the predetermined distance between them and thereby help to v assure the proper operation of the light valve.

10 Claims, 2 Drawing Figures PATENTEDJULS I975 FIG. 1

FRANCIS c. BY

BACKGROUND OF THE INVENTION This invention refers to thin panels and especially to light valves of the type in which a fluid suspension of particles is confined in-a space between two transparent plates of glass, plastic or similar material. In light valves of this type, electrically conductive transparent coatings are applied either to the inside or outside surfaces of the plates so that an electrical potential can be applied to the suspension in the space between the plates in order to activate and operate the light valve. In many applications, for example, where the. light valve is used as a window in a building or as a shutter in a camera, the panel is used in a vertical position. When this vertical dimension is large, for example, 6 to 12 inches or larger, the hydrostatic pressure of the liquid suspension causes the fluid to press outward on the plates and bows these plates into a curved surface. To overcome this, the method disclosed in U.S. Patent application Ser. No. 166,014, entitled Method for Controlling Bowing in Light Valves by Forlini et al, and assigned to the assignee of the present inventionis used. As mentioned in that application, in order to eliminate the bowing, the pressure inside the cell of thelight valve is reduced, by removing fluid, so that it is equal to or less than the pressure on theoutside of the light valve. When this is done, the pressure at some points may be lower on the inside than on the outside of the light valve. If carried far enough this can cause areverse (inward) bowing to take place. This bowing can lead to distortion in transmission of the panel and even more serious, to the conductivecoatings of the light valve coming into contact with each other and electrically shorting out the valve. This inward bowing can also be caused by many other forces. For example, when a light valve is used as a window, wind or differ ences in pressure between the inside and outside of the building can cause the same inward bowing effect. The object of this invention is then to maintain the predetermined separation between the walls in light valves to prevent any such inward bowing and also to reinforce the panels so the entire light valve is substantially stronger.

SUMMARY OF THE INVENTION I A plurality of small, inert, substantially rigid and/or non-deformable beads (bodies) are added to the fluid suspension in a light valve. These beads distribute themselves throughout the suspension and thereby prevent outside forces from causing the panel walls to come any closer to each other than a desired distance which is the smallest dimension of these beads.

BRIEFDESCRIPTION OF THE DRAWINGS PREFERRED EMBODIMENT OF THE INVENTION In FIGS. 1 and 2 are shown a typical light valve employing this invention. The light valve consists of two transparent plates 2 and 3 which are preferably constructed of plastic, glass or other strong transparent material. These plates are generally parallel or substantially parallel and are sealed around the periphery to create an enclosed cell. The cell is filled with a fluid suspension, which has particles therein which can have their orientation changed on the application of an electric or magnetic field to the suspension. This will be discussed in greater detail hereinafter. t

On the inner surfaces of the panels, surfaces 4 and S, a thin, transparent, electrically conductive coating, designated by numerals 6 and 7 is applied. These coatings are connected by suitable electrical connections to a source of energy, such as voltage source 9, preferably an AC source. Alternatively, the conductive coatings may be placed on the outside of the panels or may be placed on the inside and covered with a protective coating. This is discussed in more detail in U.S. Patent Application Ser. No. 25,541, entitled Light Valve with Flowing Fluid Suspension and assigned to the assignee of the present Application.

The suspension itself consists of particles of a substance such as herapathite suspended in a carrier such as isopentyl acetate. The particles are such that they are capable of having their orientation changed on the application of an electric or magnetic field. Before the application of a field across the suspension, the suspension will appear alm'osto'paque since the particles are not aligned. However, when a voltage field is applied across it, the particles become aligned so that the suspension will appear transparent and light will be capable of being transmitted therethrough. When the field is removed, Brownian movement will cause disorientation of the particles so that the suspension will become very dark, almost opaque, and prevent the transmission of light therethrough. The aforementioned use of herapathite and its response is mentioned in the last mentioned U.S. Patent Application Ser. No. 25,541.

However, one of the significant problems with these I light valves and the problem to which this Application is directed, is the problem of making light valves having large dimensions, especially when they are intended to be used in a vertical orientation. The problem is that the pressure of the liquid suspension in the valve causes an outward bowing of the transparent panels and a distortion of the transmissionthrough the valve. This hydrostatic pressure bowing can 'be elirninated as described inthe aforementioned U.S. Patent Application, Ser. No. 166,014. However, it is very important that when the pressure is reduced inside the light valve, in accordance with the method of this Application, that if the pressure at any point inside the cell is reduced to a point where it is less than the outside atmospheric pressure that any possibility of reverse (inward bowing) due to the difference in pressure be prevented. If there is any such reverse bowing, it is very important that it be corrected since, if it remains, there may be distortion effects similar to those that appear on outward bowing. Also, as aforementioned, inward bowing can also cause the conductive coatings to contact each other and short circuit the cell.

Briefly describing the method or reducing pressure, as stated in the aforementioned Application. The cell is first filled with the fluid suspension completely so that there are no bubbles of air in the cell. To fill the cell, one method that can be used is to employ an examount of fluid is removed or the pressure is otherwise reduced until the pressure inside the valve is substantially the same as the pressure outside the valve and the bowing is thereby completely eliminated and the cell walls become flat and parallel. The suction apparatus is then removed, the filling tube is crimped so as to prevent any air from entering the apparatus which now has a pressure inside substantially the same at at least one point as the corresponding pressure at the same point on the outside of the panel. The problem is that this method could lead to places inside the panel where the pressure is less than the pressure on the outside of the cell at the corresponding places. This could result in the undesirable inward bowing effect aforementioned.

Now, in accordance with this invention, to overcome this effect, small, substantially rigid or non-deformable beads, bits of material or other similar bodies are placed between the walls in the cell. These beads, as shown in FIG. 2, are preferably made of a hard plastic such as polycarbonate or polymethyl methacrylate, and are curved and are of a generally round or ovoid shape with one dimension being the same as the desired spacing between the panel walls (plates). The beads should also be inert with respect to the entire light valve, including the fluid suspension, the panel walls and the conductive coatings. It is especially important that they be electrically non-conductive, since if they were electrically conductive, they could provide a short circuit between the conductive coatings and distort the proper operation of the light valve. It will be appreciated that the beads can have any desired optical properties, i.e. they can be opaque, translucent or transparent and be of any color. The rounded edges on the beads are provided so that they can more readily adjust to the proper orientation between the panels. However, they can be of many other shapes. This will be discussed in more detail hereinafter.

The beads are placed in position by being mixed into the suspension before it is added to the light valve. They are mixed into the suspension by a slight stirring action so they become equally distributed throughout the suspension. Their mass density (or specific gravity) should preferably be sufficiently close to the density of the fluid suspension so that they tend to remain well distributed in the suspension without settling for at least a short amount of time after being stirred or mixed into the suspension. They are normally placed in the panel by being poured into the cell in a mixed condition with the fluid suspension. Thus, as the fluid suspension is poured into the cell, these small beads are distributed throughout the cell. The cell, at this point, is vertically positioned and completely sealed except for the opening through which the fluid suspension is poured in. A suction device (in accordance with the process of the aforementioned Patent Application) is now attached to the tube and a small amount of fluid is withdrawn until the bowing of the walls of the cell is eliminated. The walls are then flat and parallel with respect to one another, as they were originally before the fluid was added. At this point, the pressure of the fluid inside the cell has preferably been reduced to the point where it is less at many points than the pressure of the atmosphere at the corresponding points outside the cell. This would ordinarily cause the walls as aforementioned, to possibly bow inwardly to some extent. However, since the beads are present between the panel walls, and have at least one dimension which is approximately the same or slightly smaller than the desired space between the panel walls, the heads will prevent any significant inward bowing of the walls.

The beads may have curved surfaces as aforementioned. This permits them to move around so that they can be properly aligned between the walls as the walls are being drawn inward by the pressure change. If a head has one dimension that is longer than the desired spacing between the panels, the rounded edges of the bead will cause it to rotate so that its shorter dimension is properly positioned between the walls. Because of this, perfectly spherical beads of course are especially desirable. Also, by having curved surfaces and by being free to move around, thebeads can move to the point where they will be most optimally aligned and therefore capable of properly holding the plates the correct distance apart. A typical dimension for the spacing between the cell walls is 30 mils and therefore the beads for use with that cell will have one dimension of about 30 mils. As the gap between the cell walls increases or decreases the dimensions of the beads will correspondingly increase or decrease. I

The heads will not only prevent the glass walls (plates) of the panel from contacting each other, but they will also substantially strengthen the entire light valve structure since they will be held firmly in position due to the inward pressure exerted against them be each major wall. This pressure is caused by the slightly greater pressure on the outside of the cell walls than on the inside. The beads will now, in essence, form an interlocking structure so that the walls and the beads will make up an entire lattice structure to substantially strengthen the light valve. This strengthening is especially significant when the panels are very large and exposed to the atmosphere since it will strengthen the panels to the point where they can withstand substantial wind or other forces that each plate or panel may be subjected to. With wind and other external forces that are perpendicular or substantially perpendicular to the panel faces, the strengthening will be important since there is very little strength in the perpendicular direction in a conventional glass panel containing a fluid suspension. With these beads which are now an integral part of the structure, the strengthened panel will now have a strength substantially in excess of the two separate glass plates by themselves.

As an example, a panel was constructed 5 feet high by 3 feet wide, and a negative pressure of about 0.2 atmosphere was then created inside the panel near the top of the panel. Tiny, non-deformable plastic beads having a flat rectangular shape were used. The result was a cell 5 feet high having a suspension therein with out any significant inward bowing, and therefore, having a substantially uniform suspension of approximately constant thickness.

Briefly, when it is desired to reduce the outward bowing in a light valve, the valve is initially filled with a fluid suspension having rigid or non-deformable beads therein, which distribute themselves throughout the panel. The pressure in the panel is then reduced by withdrawing some of the fluid under suction conditions. The panel is then sealed hermetically. This causes the major walls of the panel to press inwardly against the beads. The beads thereby maintain the proper cell separation and also substantially strengthen the entire light valve.

This invention is also useful when the suspending fluid in the panel is a gas. Without the use of the heads, the walls of a sealed panel filled with gas will bulge inward and outward as the barometric pressure changes. When the barometric pressure (the atmospheric pressure outside the panel) decreases so that it becomes less than the pressure of the gas sealed within the panel, the walls will bulge outward. When the barometric pressure increases so that it becomes greater than the pressure of the gas sealed inside, the walls will bulge inward. The panel thus acts like the sensing element of an aneroid barometer.

This will also occur with changes in the temperature of the panel. When the panel temperature rises, as for example, when the panel is used as a window in the wall of a building facing the sun, the pressure of the gas sealed in the cell will increase, and the wallswill bulge outward. When the panel temperature drops, as for example, when the aforesaid' window is exposed to cold air in the shade, the gas pressure in the cell will drop, and the walls will bow inward toward each other.

Thus, the spacing between the walls of a gas-filled panel is quite sensitive to variations in ambient temperature and pressure; without the benefit of this invention. However, this sensitivity is eliminated by means of this invention thus: the panel is filled with the specified beads and with the gas at a pressure low enough so The optical density of the beads does not'vary as does I the optical density of the suspension. Consequently, the beads are visible at least some of the time during which the optical density of the suspension is varied. However, this visibility of the beads can be minimized in a selected range of optical densities of the suspension by one or more of'the following three methods: (1) the beads can be chosen to have an optical density approximately equal to the optical density of the suspension in the range of optical densities in which it is desired to minimize the visibility of the beads; (2) the color of the beads can be chosen to match approximately the color of the suspension; and (3) the index of refraction of the beads can be chosen to match approximately the index of refraction of the suspension.

In some applications of the light valve it is desirable to minimize the number ofbeads in the valvebecause of .the possible visibility of the beads. 0n the other hand, the number of beads, and their placement, must be sufficient to prevent the bowing of the plates as described elsewhere herein. The number of beads required for this purpose depends upon the thickness of the elastic constants of the beads, and upon the size and shape of the panel. As a general rule-of-thumb, for example, with glass plates that are 3/16 inch thick, one bead forevery 4 square inches of panel suffices.

The term "fluid" includes but is not limited to fluid suspensions.

It will be appreciated that this invention provides a highly efficient way of strengthening a light valve and for preventing inward bowing.

While specific embodiments of my invention have been illustrated, it will be appreciated that the invention is not limited thereto, since many modifications may be made by one skilled in the art which fall within the true spirit and scope of the invention l claim:

l. A method of maintaining the proper separation be tween the walls of a cell, which cell has tit least two walls which define a predetermined dimension containing a fluid comprising the steps of:

providing small non-reactive bodies in the cell which have at least one dimension substantially equal to the desired predetermined dimension between the walls and which are substantially surrounded by the fluid, and are capable of movement, and

applying a force to a wall of the cell by a pressure differential so that the bodies are held between the two walls to maintain the predetermined dimension therebetween.

2. The method of claim 1 including the step of applying forces to both walls of the cell in a direction towards each other to cause the pressure differential so that the bodies are held between the two walls.

3.'The method of claim 2 wherein the forces are caused by the pressure of the fluidin the cell on one side of a wall being lessat a point in the cell than the pressure of the fluid at the corresponding point on the other side of the wall of the cell.

4. The method of claim 3 including the step of adding the bodies to the fluid after the fluid is placed in the cell.

5. The method of claim 4 wherein the pressure in the cell before the application of the forces is a least at one point greater in the cell due to the fluid pressure than outside the cell.

6. The method of claim 5 wherein the pressure of the fluid at at least the point in the cell is reduced so that it is slightly less than the pressure outside the cell by removing some of the fluid from the cell and hermetically sealing the cell.

7. The method of claim 6 wherein the walls of the cell bow outwardly when the pressureof fluid is greater in the cell than on the outside and bow inwardly when the pressure is greater on the outside than on the inside.

8. The method of claim 7 wherein the cell is a light valve and the fluid comprises a fluid suspension containing particles which change their orientation on the application of an electric or magnetic field to affect the radiation passing through the cell.

9. The method of claim 8 wherein the outside pressure is atmospheric pressure and the suspended particles are herapathite.

10. The method of causingat least one wall of a deformed cell having at least two walls which define a predetermined dimension to return substantially to its undeformed condition by reducing the pressure of fluid inside the cell where the pressure of the fluid is at least at one point in the cell, greater than the pressure on the wall of the fluid at a corresponding point on the other side of the wall outside the cell comprising the steps of: providing small non-reactive bodies in the cell which have at least one dimension substantially equal to the desired predetermined dimension between the walls and which are substantially surrounded'by the fluid, causing the wall to return to its undeformed condition by reducing the pressure inside thecell by removing fluid until the pressure of the fluid inside walls to maintain the predetermined dimension the cell at that point is substantially equal to the therebetween, and pressure of the fluid outside the cell at that point, hermetically sealing the cell. and so that the bodies are held between the two 

1. A method of maintaining the proper separation between the walls of a cell, which cell has at least two walls which define a predetermined dimension containing a fluid comprising the steps of: providing small non-reactive bodies in the cell which have at least one dimension substantially equal to the desired predetermined dimension between the walls and which are substantially surrounded by the fluid, and are capable of movement, and applying a force to a wall of the cell by a pressure differential so that the bodies are held between the two walLs to maintain the predetermined dimension therebetween.
 2. The method of claim 1 including the step of applying forces to both walls of the cell in a direction towards each other to cause the pressure differential so that the bodies are held between the two walls.
 3. The method of claim 2 wherein the forces are caused by the pressure of the fluid in the cell on one side of a wall being less at a point in the cell than the pressure of the fluid at the corresponding point on the other side of the wall of the cell.
 4. The method of claim 3 including the step of adding the bodies to the fluid after the fluid is placed in the cell.
 5. The method of claim 4 wherein the pressure in the cell before the application of the forces is a least at one point greater in the cell due to the fluid pressure than outside the cell.
 6. The method of claim 5 wherein the pressure of the fluid at at least the point in the cell is reduced so that it is slightly less than the pressure outside the cell by removing some of the fluid from the cell and hermetically sealing the cell.
 7. The method of claim 6 wherein the walls of the cell bow outwardly when the pressure of fluid is greater in the cell than on the outside and bow inwardly when the pressure is greater on the outside than on the inside.
 8. The method of claim 7 wherein the cell is a light valve and the fluid comprises a fluid suspension containing particles which change their orientation on the application of an electric or magnetic field to affect the radiation passing through the cell.
 9. The method of claim 8 wherein the outside pressure is atmospheric pressure and the suspended particles are herapathite.
 10. The method of causing at least one wall of a deformed cell having at least two walls which define a predetermined dimension to return substantially to its undeformed condition by reducing the pressure of fluid inside the cell where the pressure of the fluid is at least at one point in the cell, greater than the pressure on the wall of the fluid at a corresponding point on the other side of the wall outside the cell comprising the steps of: providing small non-reactive bodies in the cell which have at least one dimension substantially equal to the desired predetermined dimension between the walls and which are substantially surrounded by the fluid, causing the wall to return to its undeformed condition by reducing the pressure inside the cell by removing fluid until the pressure of the fluid inside the cell at that point is substantially equal to the pressure of the fluid outside the cell at that point, and so that the bodies are held between the two walls to maintain the predetermined dimension therebetween, and hermetically sealing the cell. 